Antimicrobial, injection molded air duct for use in an air distribution system

Abstract

An antimicrobial, injection molded air duct for use in an air distribution system which delivers air to a passenger cabin of a vehicle or into an enclosed space within a residential structure is provided. The air duct includes a hollow, injection molded housing having an air passageway for communicating airflow therethrough. The housing includes a layer of molded material which at least partially defines the passageway and which absorbs airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow. The molded material includes antimicrobial agents disbursed throughout the layer to reduce the number of pathogens contained within droplets absorbed by the layer.

What is claimed is: 
     
       1. An antimicrobial, injection molded air duct for use in an air distribution system which delivers air to a passenger cabin of a vehicle, the air duct comprising:
 a hollow, injection molded housing having an air passageway configured to communicate airflow therethrough, the housing including an outer layer of molded material and a droplet-absorbing, inner surface layer of molded material compatible with the molded material of the outer layer, wherein the inner surface layer of the housing completely defines the air passageway and extends the full length of the air passageway between inlet and outlet ends of the air duct and which absorbs airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow, wherein the molded material of the inner surface layer includes antimicrobial agents dispersed throughout the inner surface layer to reduce the number of pathogens contained within liquid droplets absorbed by the inner surface layer; and 
 a turning vane disposed within the air passageway to direct a change in direction of the airflow within the air passageway, wherein the turning vane includes a droplet-absorbing surface layer having antimicrobial properties to absorb, from the airflow impacting the turning vane when being changed in direction by the turning vane, airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow, the surface layer of the turning vane including antimicrobial agents to reduce the number of pathogens within liquid droplets absorbed by the surface layer of the turning vane. 
 
     
     
       2. The air duct as claimed in  claim 1 , further comprising a mechanism disposed within the air passageway to adjust a volume of airflow to the passenger cabin wherein the mechanism includes a droplet-absorbing surface layer having antimicrobial properties. 
     
     
       3. The air duct as claimed in  claim 2 , wherein the mechanism includes a damper to control airflow within the air passageway. 
     
     
       4. The air duct as claimed in  claim 1 , wherein the air distribution system comprises an HVAC system which conditions the air provided to the passenger cabin. 
     
     
       5. The air duct as claimed in  claim 1 , wherein the molded material of the inner layer is a hydrophilic thermoplastic composition. 
     
     
       6. The air duct as claimed in  claim 1 , wherein the antimicrobial agents include antiviral agents. 
     
     
       7. The air duct as claimed in  claim 1 , wherein the housing includes first and second opposed plastic parts secured to one another about their outer perimeters in a closed configuration in which inner surface layers of the parts completely define the passageway. 
     
     
       8. The air duct as claimed in  claim 7 , wherein the parts are fused or welded together to secure the housing in the closed configuration. 
     
     
       9. The air duct as claimed in  claim 7 , wherein each of the parts is formed as a unitary molded part having a multilayered wall structure obtained by a co-injection process during injection molding or by sandwich injection molding. 
     
     
       10. The air duct as claimed in  claim 1 , wherein a portion of the turning vane is wavy to increase impact events of the airflow with the turning vane to thereby increase opportunity for the surface layer of the turning vane to absorb airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow. 
     
     
       11. An antimicrobial, injection molded air duct for use in an air distribution system which delivers air to an enclosed space within a residential structure, the air duct comprising:
 a hollow, injection molded housing having an enclosed air passageway configured to communicate airflow therethrough, the housing including an outer layer of molded material and a droplet-absorbing, inner surface layer of molded material compatible with the molded material of the outer layer wherein the inner surface layer of the housing completely defines the air passageway and extends the full length of the air passageway between inlet and outlet ends of the air duct and which absorbs airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow, wherein the molded material of the inner surface layer includes antimicrobial agents dispersed throughout the inner surface layer to reduce the number of pathogens contained within droplets absorbed by the inner surface layer; and 
 a turning vane disposed within the air passageway to direct a change in direction of the airflow within the air passageway, wherein the turning vane includes a droplet-absorbing surface layer having antimicrobial properties to absorb, from the airflow impacting the turning vane when being changed in direction by the turning vane, airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow, the surface layer of the turning vane including antimicrobial agents to reduce the number of pathogens within liquid droplets absorbed by the surface layer of the turning vane. 
 
     
     
       12. The air duct as claimed in  claim 11 , further comprising a damper disposed within the air passageway to control airflow within the air passageway, wherein the damper includes a droplet-absorbing surface layer having antimicrobial properties. 
     
     
       13. The air duct as claimed in  claim 11 , wherein the air distribution system comprises an HVAC system which conditions the air provided to the enclosed space. 
     
     
       14. The air duct as claimed in  claim 11 , wherein the molded material of the inner surface layer is a hydrophilic thermoplastic composition. 
     
     
       15. The air duct as claimed in  claim 11 , wherein the housing includes first and second opposed plastic parts secured to one another about their outer perimeters in a closed configuration in which inner layers of the parts completely define the passageway. 
     
     
       16. The air duct as claimed in  claim 15 , wherein each of the parts is formed as a unitary molded part having a multilayered wall structure obtained by a co-injection process during injection molding or by sandwich injection molding. 
     
     
       17. The air duct as claimed in  claim 11 , wherein a portion of the turning vane is wavy to increase impact events of the airflow with the turning vane to thereby increase opportunity for the surface layer of the turning vane to absorb airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow.